U.S. patent application number 13/623891 was filed with the patent office on 2014-03-27 for fibrous composite tobacco-containing materials.
This patent application is currently assigned to R.J. Reynolds Tobacco Company. The applicant listed for this patent is R.J. REYNOLDS TOBACCO COMPANY. Invention is credited to Bruce Bengtsson, Jason Kobisky, Andries Sebastian.
Application Number | 20140083438 13/623891 |
Document ID | / |
Family ID | 49301649 |
Filed Date | 2014-03-27 |
United States Patent
Application |
20140083438 |
Kind Code |
A1 |
Sebastian; Andries ; et
al. |
March 27, 2014 |
FIBROUS COMPOSITE TOBACCO-CONTAINING MATERIALS
Abstract
Smokeless tobacco products suitable for oral consumption are
provided. The smokeless tobacco products include a tobacco
composition and at least one fibrous structure enclosing at least a
portion of the outer surface of the tobacco composition such that
the fibrous structure and the tobacco composition form a cohesive
structure capable of maintaining cohesion when placed in an oral
cavity, wherein the fibrous structure includes one or more of (i) a
warp knitted structure; (ii) a plurality of reinforcing fibers
attached to the tobacco composition; (iii) a braided sleeve; and
(iv) a spacer fabric. A process for preparing a smokeless tobacco
product adapted for oral consumption is also provided, the process
including the step of enclosing at least a portion of the outer
surface of a tobacco composition with a fibrous structure to form a
composite structure.
Inventors: |
Sebastian; Andries;
(Clemmons, NC) ; Bengtsson; Bruce; (Winston-Salem,
NC) ; Kobisky; Jason; (Winston-Salem, NC) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
R.J. REYNOLDS TOBACCO COMPANY |
Winston-Salem |
NC |
US |
|
|
Assignee: |
R.J. Reynolds Tobacco
Company
Winston-Salem
NC
|
Family ID: |
49301649 |
Appl. No.: |
13/623891 |
Filed: |
September 21, 2012 |
Current U.S.
Class: |
131/111 ;
131/290; 131/352; 131/353 |
Current CPC
Class: |
A24B 13/00 20130101;
A24B 15/12 20130101; A24B 15/186 20130101 |
Class at
Publication: |
131/111 ;
131/352; 131/353; 131/290 |
International
Class: |
A24B 13/00 20060101
A24B013/00 |
Claims
1. A smokeless tobacco product adapted for oral consumption,
comprising: a tobacco composition; and at least one fibrous
structure enclosing at least a portion of the outer surface of the
tobacco composition such that the fibrous structure and the tobacco
composition form a cohesive structure capable of maintaining
cohesion when placed in an oral cavity, wherein the fibrous
structure comprises one or more of (i) a warp knitted structure;
(ii) a plurality of reinforcing fibers attached to the tobacco
composition; (iii) a braided sleeve; and (iv) a spacer fabric.
2. The smokeless tobacco product of claim 1, wherein the tobacco
composition comprises at least one of a cut, ground, pelletized,
particulate, granular, shredded, reconstituted, extruded, cast, or
compressed tobacco sheet material.
3. The smokeless tobacco product of claim 1, wherein the tobacco
composition is in the form of a compressed tobacco sheet.
4. The smokeless tobacco product of claim 1, wherein the fibrous
structure comprises fibers made from a material selected from the
group consisting of alginate, protein, cotton, nylon, viscose,
polyester, acrylics, flax, jute, bamboo, rayon, polyvinyl alcohol,
starch, polyurethane, cis-polyisoprene, polyanhydride, polybutylene
succinate, hybrid yarns formed containing glass fiber, and
copolymers and blends thereof.
5. The smokeless tobacco product of claim 1, wherein the fibrous
structure comprises fibers made from a cellulosic material or an
aliphatic polyester selected from polylactic acid and
polyhydroxyalkanoates.
6. The smokeless tobacco product of claim 1, wherein the fibrous
structure encloses at least about 50% of the outer surface area of
the tobacco composition.
7. The smokeless tobacco product of claim 1, wherein the fibrous
structure encloses at least about 90% of the outer surface area of
the tobacco composition.
8. The smokeless tobacco product of claim 1, wherein the fibrous
structure comprises a warp knitted structure.
9. The smokeless tobacco product of claim 1, wherein the fibrous
structure comprises a plurality of reinforcing fibers attached to
the tobacco composition through a tailored fiber placement (TFP)
process.
10. The smokeless tobacco product of claim 1, wherein the fibrous
structure comprises a braided sleeve.
11. The smokeless tobacco product of claim 1, wherein the fibrous
structure comprises a spacer fabric.
12. The smokeless tobacco product of claim 11, wherein the spacer
fabric comprises two fabric layers joined together by a plurality
of intermediate fibers and defining voids between the two fabric
layers, wherein the tobacco composition is positioned within the
voids of the spacer fabric.
13. The smokeless tobacco product of claim 1, further comprising an
edible film, wherein the edible film at least partially
encapsulates the tobacco composition.
14. The smokeless tobacco product of claim 1, further comprising at
least one edible film or fabric sheet positioned adjacent to the
tobacco composition to form a multi-layer structure, and wherein a
plurality of reinforcing fibers are positioned on the surface of
the multi-layer structure and attached thereto.
15. A process for preparing a smokeless tobacco product adapted for
oral consumption, comprising the step of enclosing at least a
portion of the outer surface of a tobacco composition with a
fibrous structure to form a composite structure capable of
maintaining cohesion when placed in an oral cavity, wherein the
fibrous structure comprises one or more of (i) a warp knitted
structure; (ii) a plurality of reinforcing fibers attached to the
tobacco composition; (iii) a braided sleeve; and (iv) a spacer
fabric.
16. The process of claim 15, wherein the tobacco composition
comprises at least one of a cut, ground, pelletized, particulate,
granular, shredded, reconstituted, extruded, cast, or compressed
tobacco sheet material.
17. The process of claim 15, wherein the tobacco composition is in
the form of a compressed tobacco sheet.
18. The process of claim 15, wherein the fibrous structure
comprises fibers made from a material selected from the group
consisting of alginate, protein, cotton, nylon, viscose, polyester,
acrylics, flax, jute, bamboo, rayon, polyvinyl alcohol, starch,
polyurethane, cis-polyisoprene, polyanhydride, polybutylene
succinate, hybrid yarns formed containing glass fiber, and
copolymers and blends thereof.
19. The process of claim 15, wherein the fibrous structure
comprises fibers made from a cellulosic material or an aliphatic
polyester selected from polylactic acid and
polyhydroxyalkanoates.
20. The process of claim 15, wherein the fibrous structure encloses
at least about 50% of the outer surface area of the tobacco
composition.
21. The process of claim 15, wherein the fibrous structure encloses
at least about 90% of the outer surface area of the tobacco
composition.
22. The process of claim 15, wherein the fibrous structure
comprises a warp knitted structure and the enclosing step comprises
placing the tobacco composition within a cavity formed within the
warp knitted structure and compressing the warp knitted structure
around the tobacco composition.
23. The process of claim 15, wherein the fibrous structure
comprises a plurality of reinforcing fibers attached to the tobacco
composition through a tailored fiber placement (TFP) process that
comprises the step of stitching each reinforcing fiber to the
tobacco composition.
24. The product of claim 15, wherein the fibrous structure
comprises a braided sleeve, and wherein the enclosing step
comprises placing the tobacco composition within a cavity formed
within the braided sleeve and compressing the braided sleeve around
the tobacco composition.
25. The process of claim 15, wherein the fibrous structure
comprises a spacer fabric, and the enclosing step comprises placing
the tobacco composition within the spacer fabric and collapsing the
spacer fabric around the tobacco composition.
26. The process of claim 25, wherein the spacer fabric comprises
two fabric layers joined together by a plurality of intermediate
fibers and defining voids between the two fabric layers, and
wherein the enclosing step comprises placing the tobacco
composition within the voids of the spacer fabric.
27. The process of claim 15, wherein the fibrous structure
comprises a plurality of reinforcing fibers attached to the tobacco
composition through a tailored fiber placement (TFP) process, and
wherein the composite structure further comprises at least one
edible film or fabric sheet positioned adjacent to the tobacco
composition to form a multi-layer structure, such that the tailored
fiber placement process comprises positioning the plurality of
reinforcing fibers on the surface of the multi-layer structure and
stitching each reinforcing fiber thereto.
Description
FIELD OF THE DISCLOSURE
[0001] The present invention relates to products made or derived
from tobacco, or that otherwise incorporate tobacco, and are
intended for human consumption. More particularly, the disclosure
relates to fibrous structures for encapsulating tobacco products
adapted for oral consumption.
BACKGROUND OF THE DISCLOSURE
[0002] Tobacco may be enjoyed in a so-called "smokeless" form.
Particularly popular smokeless tobacco products are employed by
inserting some form of processed tobacco or tobacco-containing
formulation into the mouth of the user. See, for example, the types
of smokeless tobacco formulations, ingredients, and processing
methodologies set forth in U.S. Pat. No. 1,376,586 to Schwartz;
U.S. Pat. No. 3,696,917 to Levi; U.S. Pat. No. 4,513,756 to Pittman
et al.; U.S. Pat. No. 4,528,993 to Sensabaugh, Jr. et al.; U.S.
Pat. No. 4,624,269 to Story et al.; U.S. Pat. No. 4,991,599 to
Tibbetts; U.S. Pat. No. 4,987,907 to Townsend; U.S. Pat. No.
5,092,352 to Sprinkle, III et al.; U.S. Pat. No. 5,387,416 to White
et al.; U.S. Pat. No. 6,668,839 to Williams; U.S. Pat. No.
6,834,654 to Williams; U.S. Pat. No. 6,953,040 to Atchley et al.;
U.S. Pat. No. 7,032,601 to Atchley et al.; U.S. Pat. No. 7,694,686
to Atchley et al.; U.S. Pat. No. 7,810,507 to Dube et al.; U.S.
Pat. No. 7,819,124 to Strickland et al.; U.S. Pat. No. 7,861,728 to
Holton, Jr. et al.; U.S. Pat. No. 7,946,296 to Wrenn et al. U.S.
Pat. No. 8,067,046 to Schleef et al.; and U.S. Pat. No. 8,151,802
to Boldrini et al.; US Pat. Pub. Nos. 2004/0020503 to Williams;
2005/0115580 to Quinter et al.; 2005/0244521 to Strickland et al.;
2006/0191548 to Strickland et al.; 2007/0062549 to Holton, Jr. et
al.; 2007/0261707 to Winterson et al.; 2008/0029110 to Dube et al.;
2008/0029116 to Robinson et al.; 2008/0029117 to Mua et al.;
2008/0173317 to Robinson et al.; 2008/0196730 to Engstrom et al.;
2008/0209586 to Neilsen et al.; 2008/0305216 to Crawford et al.;
2009/0065013 to Essen et al.; 2009/0133703 and 2009/0133704 to
Strickland; 2009/0293889 to Kumar et al.; 2010/0170522 to Sun et
al.; 2010/0291245 to Gao et al.; 2010/0300463 to Chen et al.;
2010/0300464 to Gee et al.; 2010/0303969 to Sengupta et al.;
2011/0061666 to Dube et al.; 2011/0139164 to Mua et al.;
2011/0247640 to Beeson et al.; 2011/0315154 to Mua et al.;
20120024301 to Carroll et al.; 2012/0031414 and 2012/0031416 to
Atchley et al.; 2012/0037175 to Cantrell et al.; 2012/0055493 to
Novak, III et al.; 2012/0055494 to Hunt et al.; 2012/0103353 to
Sebastian et al.; 2012/0118310 to Cantrell et al.; 2012/0138073 to
Cantrell et al.; and 2012/0138074 to Cantrell et al.; PCT Pub. Nos.
WO 04/095959 to Arnarp et al.; and WO 10/132,444 to Atchley; each
of which is incorporated herein by reference.
[0003] Representative smokeless tobacco products that have been
marketed include those referred to as CAMEL Snus, CAMEL Orbs, CAMEL
Strips and CAMEL Sticks by R. J. Reynolds Tobacco Company; GRIZZLY
moist tobacco, KODIAK moist tobacco, LEVI GARRETT loose tobacco and
TAYLOR'S PRIDE loose tobacco by American Snuff Company, LLC; KAYAK
moist snuff and CHATTANOOGA CHEW chewing tobacco by Swisher
International, Inc.; REDMAN chewing tobacco by Pinkerton Tobacco
Co. LP; COPENHAGEN moist tobacco, COPENHAGEN Pouches, SKOAL
Bandits, SKOAL Pouches, RED SEAL long cut and REVEL Mint Tobacco
Packs by U.S. Smokeless Tobacco Company; and MARLBORO Snus and
Taboka by Philip Morris USA.
[0004] It would thus be desirable to provide an improved means for
delivering compact or compressed amounts of smokeless tobacco
wherein the means of delivery provides various advantageous
features, such as ease of dispensing, use, and an overall enjoyable
form.
BRIEF SUMMARY OF THE DISCLOSURE
[0005] The present invention provides tobacco products adapted for
oral ingestion and processes for manufacturing the same. The
tobacco product includes a tobacco composition and at least one
fibrous structure adapted to encapsulate or enclose the tobacco
composition such that the fibrous structure enhances the
cohesiveness of the tobacco composition within the tobacco product.
The presence of the fibrous structure enables the resulting
composite product to maintain cohesion between the fibrous
structure and the tobacco composition when placed in the oral
cavity of the user, meaning the products of the invention are
capable of remaining essentially intact during oral use. According
to one embodiment, the tobacco composition includes at least one of
a cut, ground, pelletized, particulate, granular, shredded,
reconstituted, extruded, cast, or compressed tobacco sheet
material.
[0006] According to one aspect, the fibrous structure includes one
or more of (i) a warp knitted structure; (ii) a plurality of
reinforcing fibers attached to the tobacco composition; (iii) a
braided sleeve; and (iv) a spacer fabric. According to one
embodiment, the fibrous structure includes fibers made from
alginate, protein, cotton, nylon, viscose, polyester, acrylics,
flax, jute, bamboo, rayon, polyvinyl alcohol, starch, polyurethane,
cis-polyisoprene, polyanhydride, polybutylene succinate, hybrid
yarns formed containing glass fiber, and copolymers and blends
thereof. According to another embodiment, the fibrous structure
includes fibers made from a cellulosic material or an aliphatic
polyester selected from polylactic acid and polyhydroxyalkanoates.
According to one embodiment, the fibrous structure encloses at
least about 50% of the outer surface area of the tobacco
composition or at least about 90% of the outer surface area of the
tobacco composition.
[0007] In certain embodiments, the fibrous structure includes a
plurality of reinforcing fibers attached to the tobacco composition
through a tailored fiber placement (TFP) process. According to
another embodiment, the fibrous structure includes a spacer fabric
that includes two fabric layers joined together by a plurality of
intermediate fibers and defining voids between the two fabric
layers, wherein the tobacco composition is positioned within the
voids of the spacer fabric. According to yet another embodiment,
the tobacco product further includes an edible film. The edible
film at least partially encapsulates the tobacco composition, and
the fibrous structure typically encapsulates the edible film. In a
still further embodiment, the product contains at least one edible
film or fabric sheet (or a plurality of either material or a
combination of an edible film with a fabric sheet) positioned
adjacent to the tobacco composition to form a multi-layer
structure, and a plurality of reinforcing fibers are positioned on
the surface of the multi-layer structure and attached thereto, such
as by using a tailored fiber placement process.
[0008] According to another aspect, a process for preparing a
smokeless tobacco product adapted for oral consumption is provided.
The process includes the step of enclosing at least a portion of
the outer surface of a tobacco composition with a fibrous structure
to form a composite structure capable of maintaining cohesion when
placed in an oral cavity, wherein the fibrous structure includes
one or more of (i) a warp knitted structure; (ii) a plurality of
reinforcing fibers attached to the tobacco composition; (iii) a
braided sleeve; and (iv) a spacer fabric. According to one
embodiment, the fibrous structure includes a warp knitted structure
and the enclosing step includes placing the tobacco composition
within a cavity formed within the warp knitted structure and
compressing the warp knitted structure around the tobacco
composition. According to another embodiment, the fibrous structure
includes a plurality of reinforcing fibers attached to the tobacco
composition through a tailored fiber placement (TFP) process that
includes the step of stitching each reinforcing fiber to the
tobacco composition. According to yet another embodiment, the
fibrous structure includes a braided sleeve, and wherein the
enclosing step includes placing the tobacco composition within a
cavity formed within the braided sleeve and compressing the braided
sleeve around the tobacco composition. According to a still further
embodiment, the fibrous structure includes a spacer fabric, and the
enclosing step includes placing the tobacco composition within the
spacer fabric and collapsing the spacer fabric around the tobacco
composition. The spacer fabric can include two fabric layers joined
together by a plurality of intermediate fibers and defining voids
between the two fabric layers, and the enclosing step can include
placing the tobacco composition within the voids of the spacer
fabric. In a further version of a method utilizing a tailored fiber
placement (TFP) process, wherein the composite structure further
comprises at least one edible film or fabric sheet positioned
adjacent to the tobacco composition to form a multi-layer
structure, the tailored fiber placement process comprises
positioning the plurality of reinforcing fibers on the surface of
the multi-layer structure and stitching each reinforcing fiber
thereto.
[0009] These and other features, aspects, and advantages of the
disclosure will be apparent from a reading of the following
detailed description together with the accompanying drawings, which
are briefly described below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] Having thus described the disclosure in general terms,
reference will now be made to the accompanying drawings, which are
not necessarily drawn to scale, and wherein:
[0011] FIG. 1 is a cross-sectional view of one embodiment of a
smokeless tobacco product of the present disclosure;
[0012] FIG. 2 is an expanded view of a warp knitted fabric
according to one embodiment;
[0013] FIG. 3 illustrates the placement of a reinforcing fiber on a
base material according to tailored fiber placement process;
[0014] FIG. 4 is a cross-sectional view of a multi-layer smokeless
tobacco product that includes a plurality of reinforcing fibers
attached through a tailored fiber placement (TFP) process;
[0015] FIG. 5 is a side view of a braided sleeve according to one
embodiment;
[0016] FIG. 6 is a cross-sectional view of a spacer fabric
according to one embodiment; and
[0017] FIG. 7 is a perspective view of a tubular spacer fabric
according to one embodiment.
DETAILED DESCRIPTION OF THE DISCLOSURE
[0018] The present disclosure now will be described more fully
hereinafter with reference to certain preferred aspects. These
aspects are provided so that this disclosure will be thorough and
complete, and will fully convey the scope of the disclosure to
those skilled in the art. Indeed, the disclosure may be embodied in
many different forms and should not be construed as limited to the
aspects set forth herein; rather, these aspects are provided so
that this disclosure will satisfy applicable legal requirements. As
used in the specification, and in the appended claims, the singular
forms "a", "an", "the", include plural referents unless the context
clearly dictates otherwise.
[0019] A composite smokeless tobacco product adapted for oral
consumption is provided. According to one embodiment, the tobacco
product includes a tobacco composition and at least one fibrous
structure adapted to encapsulate or enclose the tobacco composition
such that the fibrous structure enhances the cohesiveness of the
tobacco composition within the tobacco product. The presence of the
fibrous structure enables the composite product to maintain
cohesion between the fibrous structure and the tobacco composition
when placed in the oral cavity of the user, meaning the products of
the invention are capable of remaining essentially intact during
oral use. The composite structure is adapted for oral usage and may
incorporate various fibers or yarns as disclosed herein. The
overall or cross-sectional shape of the smokeless tobacco product
of the invention can vary, and will include ovals, circles,
squares, rectangles, triangles, trapezoids, or any other shape
suitable for placement between the cheek and gum.
[0020] Reference to various forms of "enclosure" or "encapsulation"
of the tobacco composition refers to the ability of the fibrous
structure to encompass, adhere to, or be applied on or around a
tobacco composition, particularly in the context of a pocket,
pouch, or sleeve. The composite structure will not necessarily
encapsulate all surfaces of a tobacco composition such that the
fibrous structure forms the entire outer surface of the
composition, although such structures are included in the
invention. The fibrous structure could simply be present as part of
a multi-layer structure such that a significant portion of the
outer surface of a tobacco composition layer is overlaid with the
fibrous structure, but the tobacco composition is still open to the
outer surface of the product, such as at the lateral edges of a
multi-layer product. In certain embodiments, the fibrous structure
encompasses or surrounds at least about 50% of the outer surface
area of the tobacco composition, more often at least about 60%, at
least about 70%, at least about 80%, at least about 90%, at least
about 95%, or even 100% of the outer surface area (i.e., the
tobacco composition is entirely surrounded by the fibrous
structure).
[0021] The composite structures disclosed herein aid in the
delivery of tobacco products which are convenient, fresh and
flavorful. The fibrous structures described herein are safe for
oral usage such that once the fibrous structure is in combination
with a tobacco composition, the resulting tobacco product may be
stored, packaged, and delivered to the end user for placement in
the oral cavity. The various fibrous structures disclosed herein
can be used alone or in any combination with one another.
[0022] As used herein, the term "tobacco composition" includes, but
is not limited to, compositions comprising pelletized, particulate,
granular, shredded, and reconstituted tobacco (e.g., compressed or
molded pellets produced from powdered or processed tobacco, such as
those formed into the general shape of a coin, cylinder, bean,
pellet, sphere, orb, strip, obloid, cube, bead, or the like),
extruded or cast pieces of tobacco products incorporating tobacco
carried by a solid substrate (e.g., where substrate materials range
from edible grains to inedible cellulosic sticks), extruded or
formed tobacco-containing rods or sticks, compressed tobacco
sheets, tobacco-containing capsule-like materials having an outer
shell region and an inner core region, straw-like (e.g., hollow
formed) tobacco-containing shapes, sachets or packets containing
tobacco (e.g., snus-like products), pieces of tobacco-containing
gum, and the like. Further, exemplary tobacco compositions include
tobacco formulations in a loose form such as, for example, a moist
snuff product. Exemplary loose form tobacco used with the
containers of the present disclosure may include tobacco
formulations associated with, for example, commercially available
GRIZZLY moist tobacco products and KODIAK moist tobacco products
that are marketed by American Snuff Company, LLC. The tobacco
composition used in the products of the invention can also include
a tobacco extract, such as an aqueous tobacco extract. Such
extracts can be used in liquid or solid form (e.g., freeze-dried or
spray-dried form). Tobacco extracts used in the present invention
can be treated (e.g., by ultrafiltration, microfiltration,
nanofiltration, size exclusion chromatography, reverse osmosis, or
combinations thereof) as described, for example, in U.S. patent
application Ser. No. 13/240,525 to Holton Jr. et al., filed Sep.
22, 2011, which is incorporated herein by reference. Multiple types
of tobacco composition can be used in the same product, such as
combinations of a reconstituted tobacco or particulate tobacco with
a tobacco extract.
[0023] Exemplary smokeless tobacco compositions capable of use with
the present disclosure are set forth in, for example, U.S. Pat. No.
1,376,586 to Schwartz; U.S. Pat. No. 3,368,567 to Speer; U.S. Pat.
No. 4,513,756 to Pittman et al.; U.S. Pat. No. 4,606,357 to Dusek
et al; U.S. Pat. No. 4,821,749 to Toft et al.; U.S. Pat. No.
5,167,244 to Kjerstad; U.S. Pat. No. 5,387,416 to White; U.S. Pat.
No. 6,668,839 to Williams; U.S. Pat. No. 7,810,507 to Dube et al.;
U.S. Pat. No. 7,819,124 to Strickland et al.; U.S. Patent Pub. Nos.
2005/0244521 to Strickland et al.; 2006/0191548 to Strickland et
al.; and 2008/0029116 to Robinson et al. Examples of
tobacco-containing gum are set forth in U.S. Pat. No. 4,624,269 to
Story et al.; U.S. Pat. No. 4,975,270 to Kehoe; and U.S. Pat. No.
4,802,498 to Ogren. All of the above-cited references are
incorporated by reference herein in their entirety.
[0024] According to one embodiment, the tobacco composition
encapsulated within a fibrous structure according to the invention
can be contained within an existing pouch or bag. Such products
include the type commonly used for the manufacture of snus types of
products (e.g., a sealed, moisture permeable pouch that is
sometimes referred to as a "portion"). A representative moisture
permeable pouch can be composed of a "fleece" type of material. The
tobacco composition is in turn contained within a package that is
sealed tightly, and is composed of a suitable material, such that
the atmospheric conditions within that sealed package are modified
and/or controlled. Descriptions of various components of snus
products and components thereof also are set forth in US Pat. Pub.
No. 2004/0118422 to Lundin et al., which is incorporated herein by
reference. See, also, for example, U.S. Pat. No. 4,607,479 to
Linden; U.S. Pat. No. 4,631,899 to Nielsen; U.S. Pat. No. 5,346,734
to Wydick et al.; and U.S. Pat. No. 6,162,516 to Derr, and US Pat.
Pub. No. 2005/0061339 to Hansson et al.; each of which is
incorporated herein by reference. See, also, the representative
types of pouches, and pouch material or fleece, set forth in U.S.
Pat. No. 5,167,244 to Kjerstad, which is incorporated herein by
reference. Snus products can be manufactured using equipment such
as that available as SB 51-1/T, SBL 50 and SB 53-2/T from Merz
Verpackungmaschinen GmBH. G.D SpA out of Italy also supplies
tobacco pouching equipment. Snus pouches can be provided as
individual pouches, or a plurality of pouches and can be connected
or linked together (e.g., in an end-to-end manner) such that a
single pouch or individual portion can be readily removed for use
from a one-piece strand or matrix of pouches.
[0025] Tobaccos used for the manufacture of tobacco products
pursuant to the present invention may vary. The tobaccos may
include types of tobaccos such as flue-cured tobacco, burley
tobacco, Oriental tobacco, Maryland tobacco, dark tobacco,
dark-fired tobacco, dark air cured (e.g., passanda, cubano, jatin
and bezuki tobaccos) or light air cured (e.g., North Wisconsin and
galpoa tobaccos), and Rustica tobaccos, as well as other rare or
specialty tobaccos. Descriptions of various types of tobaccos,
growing practices, harvesting practices and curing practices are
set forth in Tobacco Production, Chemistry and Technology, Davis et
al. (Eds.) (1999), which is incorporated herein by reference. See,
also, the types and forms of tobacco set forth in U.S. Pat. No.
7,810,507 to Dube et al. and U.S. Pat. No. 8,061,362 to Mua et al.,
which are incorporated by reference in their entirety.
[0026] If desired, the tobacco materials can be irradiated,
pasteurized, or otherwise subjected to controlled heat treatment.
Such treatment processes are detailed, for example, in US Pat. Pub.
No. 2009/0025738 to Mua et al., which is incorporated herein by
reference. A tobacco material (or a tobacco composition comprising
a tobacco material) can be thermally treated by mixing the tobacco
material (or composition thereof), water, and an additive selected
from the group consisting of lysine, glycine, histidine, alanine,
methionine, glutamic acid, aspartic acid, proline, phenylalanine,
valine, arginine, di- and trivalent cations, asparaginase,
saccharides, phenolic compounds, reducing agents, compounds having
a free thiol group, oxidizing agents (e.g., hydrogen peroxide),
oxidation catalysts, plant extracts, and combinations thereof, to
form a moist tobacco mixture; and heating the moist tobacco mixture
at a temperature of at least about 60.degree. C. to form a
heat-treated tobacco mixture. In one embodiment, the tobacco
extract is heat treated in the presence of water, NaOH, and an
additive (e.g., lysine) at about 88.degree. C. for about 60
minutes. Such heat treatment can help prevent acrylamide production
resulting from reaction of asparagine with reducing sugars in
tobacco materials and can provide some degree of pasteurization.
See, for example, US Pat. Pub. No. 2010/0300463 to Chen et al.,
which is incorporated herein by reference.
[0027] Further components can be admixed with, or otherwise
incorporated within, the tobacco compositions according to the
invention. The additives can be artificial, or can be obtained or
derived from herbal or biological sources. Exemplary types of
additives include salts (e.g., sodium chloride, potassium chloride,
sodium citrate, potassium citrate, sodium acetate, potassium
acetate, and the like), natural sweeteners (e.g., fructose,
sucrose, glucose, maltose, vanillin, ethylvanillin glucoside,
mannose, galactose, lactose, and the like), artificial sweeteners
(e.g., sucralose, saccharin, aspartame, acesulfame K, neotame and
the like), organic and inorganic fillers (e.g., grains, processed
grains, puffed grains, maltodextrin, dextrose, calcium carbonate,
calcium phosphate, corn starch, lactose, manitol, xylitol,
sorbitol, finely divided cellulose, and the like), binders (e.g.,
povidone, sodium carboxymethylcellulose and other modified
cellulosic types of binders, sodium alginate, xanthan gum,
starch-based binders, gum arabic, lecithin, and the like), pH
adjusters or buffering agents (e.g., metal hydroxides, preferably
alkali metal hydroxides such as sodium hydroxide and potassium
hydroxide, and other alkali metal buffers such as metal carbonates,
preferably potassium carbonate or sodium carbonate, or metal
bicarbonates such as sodium bicarbonate, and the like), colorants
(e.g., dyes and pigments, including caramel coloring and titanium
dioxide, and the like), humectants (e.g., glycerin, propylene
glycol, and the like), oral care additives (e.g., thyme oil,
eucalyptus oil, and zinc), preservatives (e.g., potassium sorbate,
and the like), syrups (e.g., honey, high fructose corn syrup, and
the like), disintegration aids (e.g., microcrystalline cellulose,
croscarmellose sodium, crospovidone, sodium starch glycolate,
pregelatinized corn starch, and the like), flavorant and flavoring
mixtures (e.g., vanilla, coffee, chocolate, cream, mint, spearmint,
menthol, peppermint, wintergreen, lavender, cardamon, nutmeg,
cinnamon, clove, cascarilla, sandalwood, honey, jasmine, ginger,
anise, sage, licorice, lemon, orange, apple, peach, lime, cherry,
eucalyptus, strawberry, or mixtures thereof), antioxidants, and
mixtures thereof. If desired, the additive can be microencapsulated
as set forth in US Patent Appl. Pub. No. 2008/0029110 to Dube et
al., which is incorporated by reference herein. In addition,
exemplary encapsulated additives are described, for example, in WO
2010/132444 A2 to Atchley, which has been previously incorporated
by reference herein. Exemplary smokeless tobacco components are set
forth in US Patent Appl. Pub. Nos. 2012/0037175 to Cantrell et al.;
2012/0055494 to Hunt et al.; 2012/0103353 to Sebastian et al.;
2012/0118310 to Cantrell et al.; 2012/0138073 to Cantrell et al.;
and 2012/0138074 to Cantrell et al., which is incorporated by
reference herein.
[0028] As used herein, the term "fibrous structure" refers to a
fibrous material capable of forming a structure suitable for
encapsulation of a tobacco composition such as, for example, a
smokeless tobacco composition, and which is suitable for human
consumption. The fibrous structures as disclosed herein may be
manufactured from a variety of stable natural, semi-synthetic, and
synthetic fibers or yarns that are suitable for oral usage and
capable of comfortably conforming to the area between the gum and
cheek or lip. The fibrous structure incorporated structural
elements that are distinct from the fleece-like materials
conventionally associated with snus products. Suitable materials
include, for example, alginate, protein (e.g., soy, milk), cotton,
nylon, viscose, polyester (including aliphatic polyesters),
acrylics, flax, jute, bamboo, rayon, polyvinyl alcohol, starch,
aliphatic polyurethanes, cis-polyisoprene, polyanhydrides,
polybutylene succinate, and copolymers and blends thereof, as well
as hybrid yarns formed from high performance fibers such as glass
fiber. In one embodiment, the fibrous material is a cellulosic
material, such as regenerated cellulose, cellulose acetate,
cellulose triacetate, cellulose nitrate, ethyl cellulose, cellulose
acetate propionate, cellulose acetate butyrate, hydroxypropyl
cellulose, methyl hydroxypropyl cellulose, and the like. Exemplary
aliphatic polyesters include polyglycolic acid (PGA), polylactic
acid (PLA) (e.g., poly(L-lactic acid) or poly(DL-lactic acid)),
polyhydroxyalkanoates (PHAs) such as polyhydroxypropionate,
polyhydroxyvalerate, polyhydroxybutyrate, polyhydroxyhexanoate, and
polyhydroxyoctanoate, polycaprolactone (PCL), polybutylene
succinate, polybutylene succinate adipate, and copolymers thereof
(e.g., polyhydroxybutyrate-co-hydroxyvalerate (PHBV)). The chosen
material may vary depending on the chosen manufacturing technique
and the desired properties (e.g., desired level of
biodegradability). According to one embodiment, the fiber or yarn
has a linear mass density of typically from about 1.5 denier to
about 50 denier.
[0029] The thickness of the fibrous structures described herein may
vary, but will typically be of sufficient thickness to provide
rigidity, strength, and support to the tobacco composition (e.g., a
loose or compressed tobacco composition) and to remain intact
during oral use. The thickness of the fibrous structures (and the
overall composite product) can also depend on the desired taste
level or feel within the user's mouth.
[0030] Any of the further components or additives noted above with
respect to the tobacco composition could also be added to the
fibrous structure portion of the composite structure of the
invention, such as in the form of a coating or even imbedded in the
fibrous material. In particular, flavorants could be incorporated
into the fibrous structure to further enhance the sensory
characteristics of the product.
[0031] The manner in which the fibrous structure and the tobacco
composition are combined to form the smokeless tobacco product can
vary. Typically, the process involves enwrapping or encircling a
tobacco composition with a fibrous structure to at least partially
enclose the tobacco composition. The fibrous structure and the
tobacco composition are typically brought into intimate contact
such that the combination forms a cohesive product. In certain
embodiments, the fibrous structure will be preformed into a
pouch-like or cylindrical shape that defines an interior
compartment and the tobacco composition can be placed within the
interior compartment. Thereafter, the fibrous structure can be
compressed around the tobacco composition and the opening can be
stitched closed or otherwise shut to prevent leakage of the tobacco
composition from the fibrous structure. In other embodiments, the
tobacco composition is placed on a fibrous structure in flat,
sheet-like form and thereafter the fibrous structure is wrapped
around the tobacco composition and secured.
[0032] The size of the openings present in the fibrous structure
(e.g., the size of openings in a knitted or braided mesh) can vary,
but will typically be small enough to prevent significant leakage
of the tobacco composition from the product. The size necessary to
accomplish this function will vary depending on the structure of
the tobacco composition. A finely-divided particulate tobacco
composition will require smaller mesh openings than a compressed
tobacco sheet.
[0033] The relative amount of the fibrous structure and the tobacco
composition can vary widely depending on the desired properties of
the final product. Typically, the fibrous structure will contribute
about 1 to about 99 percent by weight (e.g., about 10 to about 80
percent by weight) of the smokeless tobacco product. In certain
embodiments, the fibrous structure is the predominate component of
the product, such as in the case of products comprising more than
about 50 percent by weight of fibrous structure based on the total
weight of the product (e.g., products containing greater than about
60 percent by weight or greater than about 70 percent by weight of
the fibrous structure). In other embodiments, the tobacco
composition is the predominate component, such as in the case of
products comprising more than about 50 percent by weight of tobacco
composition based on the total weight of the product (e.g.,
products containing greater than about 60 percent by weight or
greater than about 70 percent by weight of the tobacco
composition).
[0034] Typically, the amount of tobacco composition within each
individual portion (e.g., within each composite product) is such
that there is at least about 50 mg, often at least about 150 mg,
and frequently at least about 250 mg, of dry weight tobacco; and
less than about 700 mg, often less than about 500 mg, and
frequently less than about 300 mg, of dry weight tobacco. In one
typical embodiment, the amount of tobacco composition within each
composite product is between about 100 mg and about 400 mg.
[0035] FIG. 1 provides a cross-sectional view of an embodiment of a
smokeless tobacco product 10 of the present disclosure. As
illustrated, the tobacco product 10 includes a fibrous structure 12
as described herein that encapsulates a tobacco composition layer
14. The number of layers of the tobacco composition 14 and the
number of layers of fibrous structure 12 can vary, and the
illustrated embodiment is merely exemplary. As shown, the fibrous
structure 12 can completely surround the outer surface of the
tobacco composition 14, although embodiments where a smaller
percentage of the outer surface of the tobacco composition is
enclosed are also included in the invention. The tobacco product
may optionally include an edible film 16, explained more fully
below, that encapsulates the tobacco composition 14 in addition to
the fibrous structure. In the illustrated embodiment, the tobacco
layer 14 is in the form of a compressed tobacco sheet, although
other tobacco composition types could also be used.
[0036] The tobacco composition as illustrated in FIG. 1 may be
manufactured by a direct compression process or by a granulation
process prior to encapsulation within the fibrous structure. The
direct compression process includes a blending and processing step
which may be conducted by first forming a tobacco blend. As
indicated above, the tobacco may comprise a blend of various types,
shapes, sizes, and cuts, or a single variety of the aforementioned
tobaccos may be used instead of a blend. The tobacco may be cured
or uncured. The tobacco blend is typically further processed
through the use of a grinding step. The ground tobacco will
typically have an average particle size of less than about 1 mm.
After grinding, the tobacco component may be optionally cooked
(semi-pasteurized) by any suitable technique. For example, the
tobacco component can be cooked by high pressure, heat and/or
steam. Other cooking techniques can also be used. Following
cooking, the tobacco component may be stored at or about room
temperature until needed for further processing.
[0037] According to one embodiment, the fibrous structure 12 is a
warp knitted structure. Referring to FIG. 2, an expanded view of a
typical warp knitted fabric 20 is illustrated. Interlinking,
sequential loops 22 of a fiber or yarn are formed in an axial
direction during the stitching process on a lateral array of
needles with at least one separate thread being supplied to each
needle. A stitch is formed by wrapping the yarn around the needle
and drawing it through the previously knitted loop. This wrapping
of the yarn is referred to as an "overlap." The second component of
stitch formation is the length of yarn linking together the
stitches which is referred to as the "under lap" and is formed by
the lateral movement of the yarns across the needles.
[0038] The yarn may be manufactured from any natural or synthetic
fiber that is suitable for oral introduction and capable of
providing structural integrity to a tobacco composition as
described herein. The warp knitted structure can be formed in a
variety of shapes and sizes capable of encapsulating a tobacco
composition. The warp knitted structure provides the requisite
structural integrity required to retain the tobacco composition in
a tight, compressed form while allowing the tobacco composition to
come in contact with the user's gum, lip or cheek.
[0039] A warp knitted structure for encapsulating a tobacco
composition may be prepared via a variety of techniques. See, for
example, U.S. Pat. No. 2,435,897 to Newman et al.; U.S. Pat. No.
3,222,893 to Busch et al.; and U.S. Pat. No. 4,015,451 to Gajjar et
al., which are incorporated by reference herein. Production may be
carried out on, for example, one of two common types of warp
knitting machines: the Tricot and Raschel machines. During
production, the yarn is supplied to a knitting zone parallel to the
selvage of the fabric (i.e. in the direction of the wales). The
loops are joined together in a width-wise direction by moving the
threads back and forth between adjacent needles. The needles
produce parallel rows of loops simultaneously that are interlocked
in a zigzag pattern. Specifically, the yarns are fed from warp
beams to a row of needles extending across the width of the
machine. Every knitting needle is supplied with at least one
separate yarn. In order to connect the stitches to form a fabric,
the yarns are deflected laterally between the needles. In this
manner, a knitting needle often draws the new yarn loop through the
knitted loop formed by another end of yarn in the previous knitting
cycle. The resulting fabric can be produced in sheet or flat form
using one or more sets of warp yarns suitable for encapsulation of
a tobacco composition. The resulting fabric can be used to encircle
or enclose any desired percentage of the outer surface of the
tobacco composition in order to form a cohesive composite structure
suitable for oral use.
[0040] According to another embodiment, the fibrous structure is a
fiber reinforced composite structure manufactured according to a
tailored fiber placement (TFP) process. See, for example, the
tailored fiber placement technology platform available from Filacon
Technologies of Winterlingen, Germany and LayStitch Technologies of
Highland, Mich. See also U.S. Pat. No. 7,942,993 to Gessler et al.
and US Pat. Pub. No. 2010/0126652 to Joern et al., each of which is
incorporated by reference.
[0041] A fiber-reinforced composite structure may be manufactured
according to a tailored fiber placement process on customary
CNC-controlled automatic sewing and embroidering machines, which
are also used, for example, in the textile industry. As illustrated
in FIG. 3, during a tailored fiber placement process, one or more
reinforcing fibers 30 are sewed by needle and thread onto a base
material 32 that is held in a frame 34 (e.g., each reinforcing
fiber is stitched to the base material using a sewing technique).
In the present invention, the base material 32 includes a tobacco
composition, such as a compressed tobacco sheet. The base material
can also be a multi-layer structure that includes at least one
tobacco composition layer and at least one fibrous layer (e.g., a
fabric sheet). The reinforcing fibers 30 are stitched to the base
material (e.g., to the tobacco composition and/or to a multi-layer
structure that includes a fabric or yarn layer and a tobacco
composition layer). The reinforcing fibers 30 can be laid out in a
variety of directions and geometrical designs. Exemplary machines
capable of adaptation to form the products of the invention are
commercially available from LayStitch Technologies.
[0042] According to one embodiment, the reinforcing fibers can be
laid in either a free or selective manner. A free fiber design
allows for increased tensile strength thereby allowing for
increased ability to hold a tobacco composition in a finite space
for oral placement. A selectively laid fiber placement allows for
fiber placement at a particular point for reinforcement (e.g.,
around perimeter of the composite structure). The stitching thread
can be any biocompatible thread material known in the textile arts,
such as thread formed from one of the polymer materials noted
above.
[0043] According to one embodiment, the reinforcing fibers can be
repeatedly laid to provide any particular area of the structure
with proper reinforcement. Reinforcement can be formed specifically
in zones that are subjected to particular loading, such as, for
example, regions where force is introduced, by laying additional
fiber strands. According to one embodiment, a tobacco composition
is placed within the frame and on top of a fibrous layer, and then
reinforcing fibers are stitched over the fibrous layer and through
the tobacco composition. According to another embodiment, at least
two fibrous layers encompass or sandwich the tobacco composition
and reinforcement encapsulates the entire composite structure.
According to yet another embodiment, at least two edible or soluble
films adapted for oral ingestion may encapsulate the tobacco
composition and the reinforcement may encapsulate the entire
composite structure. The edible film includes one or more of (i) a
fruit or vegetable puree and (ii) a denatured protein. The edible
film or fibrous layer may further include one or more flavorant,
flavor enhancer, sugar or other sweetener, souring agent,
preservative, filler, pigment, or a combination thereof. Exemplary
edible films are set forth, for example, in U.S. Pat. No. 5,543,164
to Krochta et al. and U.S. Pat. No. 8,048,466 to McHugh et al., as
well as in U.S. application Ser. No. 13/530,145 to Sebastian et
al., filed Jun. 22, 2012, all of which are incorporated by
reference herein. A commercially available embodiment of an edible
film suitable for use in the present invention is available from
NewGem Foods, LLC of Stockton, Calif.
[0044] FIG. 4 presents a cross-sectional view of a smokeless
tobacco product that includes a plurality of reinforcing fibers
attached through a tailored fiber placement (TFP) process. As
illustrated, the smokeless tobacco product 40 includes a base
material that includes a tobacco composition 42 as described
herein. The tobacco composition 42 is encapsulated by optional
outer layers 44. The optional outer layers 44 may include at least
one fibrous structure (e.g., a woven or non-woven fabric sheet), at
least one edible film, or a combination thereof. For example, both
outer layers 44 can be a fabric sheet constructed of any of the
fiber types noted herein. Alternatively, both outer layers 44 could
be edible films. Still further, in certain embodiments, the
smokeless tobacco product 40 includes one edible film as a first
outer layer 44 and one fabric sheet as a second outer layer 44.
Although two outer layers are illustrated in FIG. 4, the invention
also includes embodiments comprising only one outer layer 44, which
can be either a fabric sheet or an edible film. A plurality of
reinforcing fibers 46 are laid out on the base material in a
variety of directions and geometrical designs.
[0045] According to yet another embodiment, the fibrous structure
is a braided fiber sleeve. Referring to FIG. 5, the braided sleeve
50 includes a plurality of fibers 52 arranged in a crisscross
manner. The braided sleeve 50 ensures the tobacco composition
located within the sleeve remains compressed or compacted, thereby
restricting the tobacco composition from easily falling out of the
sleeve and into a user's mouth. The physical properties of the
braid (expandability, compressibility, resiliency, stretchability)
can be adjusted to provide the ideal degree of flexibility and
structural integrity for any particular application. The braided
fiber sleeve 50 can be formed from fibers that are safe for oral
use, such as those noted above.
[0046] The braided fiber sleeves as described herein can be
prepared by conventional circular braiders. See, for example, U.S.
Pat. No. 1,615,587 to Klein et al., U.S. Pat. No. 4,734,685 to Kite
et al., U.S. Pat. No. 5,505,117 to Dunlap et al., and U.S. Pat. No.
5,749,280 to Scherzinger, which are incorporated by reference in
their entirety. A circular braiding machine is composed of two
rotating sets of bobbins on which fibers or yarns have been wound.
One set of bobbins runs clockwise while the other bobbin runs
counterclockwise around the center of the machine along a defined
path. The bobbins of the two sets pass alternatively inside and
outside along the path, forming a braided sleeve structure. The
width of the sleeve is determined by the take-up speed of the
braiding machine. According to one embodiment, the braided sleeve
can be braided on a suitable mandrel or core to produce a variety
of complex shapes, including flattened sleeves. A braided fiber
sleeve can be manufactured such that when no external forces are
applied, the sleeve remains in an unexpanded position. The sleeve
can be expanded by inserting a tobacco composition. Once the
tobacco composition is inserted, the braided fabric sleeve springs
back thereby restricting the tobacco composition and preventing
leakage of tobacco into the user's mouth. The tobacco composition
can be inserted into the braided fabric structure during
manufacture, such as by wrapping a compressed tobacco sheet around
a mandrel and braiding the fabric onto the tobacco sheet, or after
braiding by simply inserting the tobacco composition into an open
end of the braided material. The braided sleeve can be stitched
closed as desired to completely encapsulate the tobacco
composition.
[0047] According to a further embodiment, the fibrous structure is
a spacer fabric. A "spacer fabric" encompasses three-dimensional
fibrous constructions that include two distinctive layers of fabric
joined together by intermediate fibers to define a plurality of
voids between the distinctive fabric layers. In certain
embodiments, the spacer fabric is collapsible such that the spacer
fabric is capable of compressing around the tobacco composition to
create a cohesive product. See, for example, U.S. Pat. No.
7,060,156 to Mack et al., which is incorporated by reference
herein. The fabric layers disclosed herein can be constructed
uniformly or with many combinations of woven or non-woven
structures and with a wide variety of fabric and yarn fiber types.
The yarn fiber is preferably a material suitable for encapsulation
of a tobacco composition and safe for oral use as disclosed herein.
The yarn fiber structure may be ply, twisted, core-spun,
core-wrapped, or commingled. The connecting layer can be formed in
a variety of shapes including tubes, pleats, or other engineered
forms. The choice of fiber for the connecting layer can be widely
varied and the selection thereof is influenced by the mechanical
characteristics of the fabric layer material so as to provide
support and spacing between the fabric layers. According to one
embodiment, the connecting layer fiber is the same fiber as the
fiber forming the fabric layers. In an alternative embodiment, the
connecting layer fiber is different from the fiber forming the
fabric layers.
[0048] According to the embodiment of FIG. 6, the spacer fabric 60
includes a top layer 62, connecting layer 64, and a bottom layer
66. As illustrated, the top layer 62 and bottom layer 66 are
manufactured from identical yarns with identical structures. In
other embodiments, the top layer 62 and bottom layer 66 are
manufactured from different yarns and have completely different
structures.
[0049] As disclosed herein, the resulting spacer fabric may be
formed in a variety of shapes suitable for encapsulation of a
tobacco composition. According to the embodiment of FIG. 7, the
spacer fabric 70 is formed in a tubular, cylindrical, or
curvilinear shape whereby a tobacco composition is held in a cavity
72 defined by the spacer fabric. The tobacco composition can be
placed within the cavities or voids formed in the spacer fabric
between the two layers. Compression of the spacer fabric can help
retain the tobacco composition (e.g., tobacco in particulate or
granular form) within the fabric structure to form a cohesive
composite product.
[0050] A spacer fabric may the manufactured by a variety of
processes including, but not limited to, nonwoven, woven, braided,
stitched, warp knitted, weft knitted techniques, or combinations
there. According to one embodiment, a nonwoven spacer fabric is
formed from fibers that are connected by entanglement or bonded
together by a chemical, heat or solvent treatment. See, for
example, U.S. Pat. No. 7,718,249 and U.S. Pat. No. 7,814,625, both
to Russell et al., each of which is incorporated by reference
herein.
[0051] According to one embodiment, a woven spacer fabric is formed
by weaving two layers of fabric together with pile yarns binding
the two layers together so as to create a hollow space between the
two layers. See, for example, U.S. Pat. No. 5,413,837 to Rock et
al., which is incorporated by reference. According to another
embodiment, a braided spacer fabric is formed by a braiding
technique whereby three or more threads interlace with one another
in a diagonal formation, producing flat, tubular or solid
constructions. According to another embodiment, a stitched spacer
fabric is formed by a stitching process whereby stitching threads
are used to join two or more fabric layers.
[0052] According to one embodiment, a warp knitted spacer fabric is
formed by warp knitting techniques whereby yarns are formed in a
zigzag pattern along the length of a fabric and follow adjacent
columns (e.g., wales). See, for example, U.S. Pat. No. 5,385,036 to
Spillane et al., which is incorporated by reference herein. A
three-dimensional warp knitted fabric may be formed on a double-bed
Rashel machine by knitting the top and bottom layers simultaneously
on separate needle beds. During the knitting process, yarns are
intermittently swapped between the separate needle beds to create a
core of pile which is interconnected to the top and bottom layers.
The spacer fabric thickness may be adjusted appropriately by
adjusting the distance between the two needle bars.
[0053] According to yet another embodiment, a weft knitted spacer
fabric may be formed from a top layer fabric and bottom layer
fabric that is connected vertically with pile yarns. See, for
example, U.S. Pat. No. 5,735,145 to Pernick, U.S. Pat. No.
5,284,031 to Stoll et al., U.S. Pat. No. 5,422,153 to Miyamoto,
U.S. Pat. No. 5,395,684 to Robinson et al., U.S. Pat. No. 6,779,369
to Shepherd, and U.S. Pat. No. 7,611,999 to McMurray, each of which
is incorporated by reference. The top layer and bottom layer fabric
may be produced separately on a dial and cylinder machines using a
variety of stitches. Pile yarns then connect the top layer and
bottom layer by tuck stitches. Dial and cylinder machines may
produce a spacer fabric that is circular knitted. Alternatively,
dial and cylinder machines may produce a double or single-faced
cylindrical or curvilinear shaped spacer fabric. According to yet
another embodiment, a weft knitted spacer fabric may also be
manufactured on a v-bed flat knitting machine. Utilization of a
v-bed knitting machine allows of inclined or perpendicular pile
yarns and further enables a variety of structures, combinations of
different yarn materials, and further integration of one or more
additional fabrics layers and pile yarns for further
reinforcement.
[0054] Products of the present invention may be packaged and stored
in any suitable packaging. See, for example, the various types of
containers for smokeless types of products that are set forth in
U.S. Pat. No. 7,014,039 to Henson et al.; U.S. Pat. No. 7,537,110
to Kutsch et al.; U.S. Pat. No. 7,584,843 to Kutsch et al.; U.S.
Pat. No. 7,946,450 to Gelardi et al.; U.S. Pat. No. 8,033,425 to
Gelardi; U.S. Pat. No. 8,066,123 to Gelardi; U.S. Pat. No. D592,956
to Thiellier; U.S. Pat. No. D594,154 to Patel et al.; and U.S. Pat.
No. D625,178 to Bailey et al.; US Pat. Pub. Nos. 2008/0173317 to
Robinson et al.; 2009/0014343 to Clark et al.; 2009/0014450 to
Bjorkholm; 2009/0250360 to Bellamah et al.; 2009/0230003 to
Thiellier; 2010/0084424 to Gelardi; 2010/0133140 to Bailey et al;
2010/0264157 to Bailey et al.; 2011/0168712 to Gelardi et al.; and
2011/0204074 to Bailey et al., which are incorporated herein by
reference. Various manners or methods for packaging smokeless
tobacco compositions are also set forth in US Patent Pub. Nos.
2004/0217024 and 2006/0118589 to Arnarp et al.; and 2009/0014450 to
Bjorkholm; and PCT Pub. Nos. WO 2006/034450 to Budd; WO 2007/017761
to Kutsch et al.; and WO 2007/067953 to Sheveley et al, which are
incorporated by reference herein.
[0055] Many modifications and other aspects of the disclosure set
forth herein will come to mind to one skilled in the art to which
the disclosure pertains having the benefit of the teachings
presented in the foregoing descriptions and the associated
drawings. Therefore, it is to be understood that the disclosure is
not to be limited to the specific aspects disclosed and that
modifications and other aspects are intended to be included within
the scope of the appended claims. Although specific terms are
employed herein, they are used in a generic and descriptive sense
only and not for purposes of limitation.
* * * * *